Sign with inlaid letters

ABSTRACT

Grooves routed in a wooden base to form figures are filled at least partially with a thermosetting polyester resin to form a sign. A chamfer around each figure increases the field of readability of the sign and reflective beads are sprinkled on the resin prior to setting. The sign is then dropped from an elevated position onto a support to embed the beads in the resin so that, when the resin hardens, the beads are held securely against loosening.

Unite States at-ent 1 1 1111 3,852,145

Kloweit Dec. 3, 1974 [5 SIGN WITH INLAlD LETTERS 2,411,187 11/1946 Boogher 40/135 3 226, l 1966 B d 40 135 [76] Inventor: Kenneth R. Kloweit, 1304 Leaman 865 ran Pl., Rockford, 111. 61108 Primary Examiner-Wrlham E. Schulz [22] Flled: 16, 1973 Attorney, Agent, or Firm-C. Frederick Leydig [21 Appli No.: 416,615

[57] ABSTRACT I [52] Cl ggg/ i Grooves routed in a wooden base to form figures are filled at least partially with a thermosetting polyester [51] Int. Cl B44f 7/00 resin to form a Sign A chamfer around each figure [58] Field of Search 161/18; 140/125, 135, 136,

l40/152 D9 6/12 R creases the field of readablllty of the sign and reflective beads are sprinkled on the resin prior to setting. The sign is then dropped from an elevated position [56] References cued onto a support to embed the beads in the resin so that, UNITED STATES PATENTS when the resin hardens, the beads are held securely 2,003,126 5/1935 Torstenson 40/135 against loosening. 2.298364 10/1942 Gits et a1. 40/136 2,379,702 7/1945 Gebhard 40/135 X 6 Claims, 5 Drawing Figures SIGN WITH INLAID LETTERS BACKGROUND OF THE INVENTION This invention relates generally to a sign and, more particularly, to a wooden base sign in which grooves within the base form the figures of the sign and are filled at least partially with a material to give the sign an engraved appearance. In addition, the outer surface of the material is reflectorized so the sign is more readily visible at night. A sign of this general type is disclosed in Boogher U.S. Pat. No. 2,411,187. Another patent which may be considered to be relevant to the prosecution of the application on the present invention is Gits, et al., U.S. Pat. No. 2,298,364.

SUMMARY OF THE INVENTION polyester resin into grooves to a level approximately even with the inner edge of the chamfer so as to form an engraved like figure having an inlaid interior, the figure advantageously being formed without having to pre-cut the inlaid interior portion thereof while also being able to be read more easily from sharp angles relative to the outer surface of the sign.

The invention also resides in the novel construction of the base so as to captivate the thermosetting resin within the grooves and in the novel manner of reflectorizing the outer surface of each of the figures with glass beads so that the beads are much less likely to weather and loosen during the natural life of the sign.

These and other objects and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary perspective view of a sign embodying the novel features of the present invention and showing parts broken away for clarity of illustration.

FIG. 2 is an enlarged cross-sectional view taken substantially along line 2--2 of FIG. 1.

FIGS. 3, 4 and 5 are views similar to FIG. 2 but showing successive steps in the formation of the sign.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT partially with a material 15 so the figures of the sign appear to be engraved in the base. In order for the sign to be read more easily at night, the exposed surface 16 of the material is reflectorized such as by means of reflective glass beads 17 (see FIG. 4).

In accordance with the primary aspect of the present invention, the sign 10 is made more easily and less expensively while being easier to read even at sharp angles relative to the outer surface 14 of the sign and while the figures of the sign still have an engraved appearance. For these purposes, the material 15 in each of the grooves 13 is a fluid plastic poured into the grooves to a level approximately even with the inner edge 19 of a chamfer 20 formed around each groove. Advantageously, the chamfer has the effect of increasing the field of readability of the figure thereby enabling the sign to be read easily even at a relatively sharp angle with respect to the outer surface of the base without any loss in the engraved appearance of the figures of the sign. To complete the sign, the reflective glass beads are placed on the exposed surface 16 of the plastic and are embedded in the plastic such as by means of dropping the base from an elevated position onto a support prior to the hardening of the plastic in the grooves. Thus, the sign maybe made easily and quickly without the need of having to paint the interior of the grooves or to inlay pre-cut pieces within the grooves. Also, by virtue of the unique and easy manner of embedding the beads in the plastic, the beads are much less likely to loosen from the plastic due to weathering so that the life of the sign is greatly increased.

In the present instance, the plastic material 15 used informing each of the figures of the sign is a suitable thermosetting polyester resin such as is manufactured by Fibre Glass-Evercoat Co., Inc. of Cincinnati, Ohio and identified as F iberglass-Evercoat FE 2300 colorless finish coat which may be colored as desired with a suitable powder pigment. For convenience of description, hereinafter only one of the figures of the sign will be described in detail, it being appreciated that the other figures are formed in an identical fashion.

To make the sign 10 the groove 13 is formed in the base 11 with a usual router (not shown) with side walls 21 (FIG. 2) extending generally perpendicular tothe outer surface 14 of the base ll. Then, the upper edges of the side walls are beveled to form the chamfers 20 completely around each of the figures. Herein, the chamfers are beveled at an angle of about 45 in relation to the outer surface 14 of the base so the chamfer slants away from the grooveupon progressing outwardly toward the outer surface from within the base. Accordingly, this increases substantially the field of complete readability of the sign, as represented by the included angle A between opposing sides of the figure as shown in FIG. 3. In addition, the chamfer on each side of the figure provides a field of partial readability as measured by the angle B further enabling the figure to be read from an even sharper angle relative to the outer surface of the base.

Formed in the base 11 adjacent the bottom of the groove 13 are several cavities 23 which extend into the base in a generally lateral direction relative to the groove. When the plastic resin 15 is poured into the groove, the resin flows into the cavities so that, when the resin hardens to form an inlay within the groove, the inlay is locked within the groove. While in the present instance the cavities are in the form of a small punched holes slanting into the base and away from the groove, it will be appreciated that other forms of cavities also would serve for present purposes. For instance, the groove itself could be routed with a dovetail cross-sectional shape with the inward end portion of the dovetail serving as the cavity.

Preferably, the plastic resin 15 is poured into the groove 13 (see FIG. 3) as the base 11 rests horizontally on a support (not shown) such as the top of a work table to a level even with the inner edge 19 of the chamfer 20 to take full advantage of the increased full field of readability provided by the chamfer while still providing a figure having an engraved appearance. If-

desired, however, the resin may be poured to a lesser or greater depth to increase the engraved effect produced by the groove or to make the figures to appear to be more of an inlaid character. Before the resin hardens, the reflective glass beads are sprinkled on the exposed outer surface 16 of the resin (see FIG. 4). Then, the base of the sign is lifted from the support, herein about 6 inches, and while keeping the base disposed horizontally is dropped against the support. Advantageously, this causes the beads 17 to embed in the resin 15 as shown in FlG. so that, when the resin hardens, the beads are held securely on the exposed surface of the figure and thus are kept from being easily loosened as a result of weathering.

From the foregoing, it is seen that the sign 10 can be made easily and inexpensively by simply routing the grooves 13in the base 11, beveling the upper edges of the grooves to form the chamfers 20 and filling the grooves with the thermosetting polyester resin 15 level with the lower edges 19 of the chamfers, sprinkling the glass beads 17 on the outer surface 16 of the resin and dropping the base to embed the beads in the resin so that'when it hardens the beads are locked in place. Advantageously, the sign made by this process is virtually weather-proof with both the beads and the resin being securely locked in the base. Moreover, the sign is constructed so as to provide a pleasing engraved appearance while also having a greatly increased field of readability.

I claim as my invention:

1. A sign with intelligible figures having en engraved appearance comprising a wooden base with a planar outer surface, an outwardly opening groove formed within said base and defining one of said figures, a thermosetting plastic inlay partially filling said groove and having an exposed surface spaced inwardly of and extending generally parallel with the outer surface of said base, a plurality of reflective beads embedded within said inlay, a cavity formed adjacent the bottom of said groove and extending laterally thereof into said base, a portion of said inlay being received within said cavity to lock said inlay within said groove, and a chamfer formed in said base and around said groove so as to slant away from said groove upon progressing outwardly from the exposed surface of the inlay toward the outer surface of said -base thereby increasing the field of readability of said figure.

2. A sign with intelligible figures having an engraved appearance comprising a base with a planar outer surface, an outwardly opening groove formed within said base ahd defining one of said figures, a thermosetting plastic inlay partially filling said groove and having an exposed surface spaced inwardly of and extending generally parallel with the outer surface of said base, and a chamfer formed in said base and around said groove so as to slant away from said groove upon progressing outwardly from the exposed surface of the inlay toward the outer surface of said base thereby increasing the field of readability of said figure.

3. A method for making a sign with intelligible figures in a base comprising the steps of forming an outwardly opening groove within said base, filling the groove at least partially with a fluid plastic, placing a plurality of reflective beads on the exposed surface of said plastic, and embedding-the beads within the fluid plastic by elevating and dropping said base onto a support prior to hardening of the plastic to form an inlay within the groove.

4. A method for making a sign with intelligible figures having an engraved appearance in a wooden base comprising the steps of forming an outwardly opening groove within the outer surface of said base to define one of said figures, beveling the base around the edge of said groove to form a chamfer which slants away from said groove upon progressing outwardly from within said base toward the outer surface thereof, pouring a thermosetting plastic into said groove to a level approximately even with the inner edge of the chamfer, sprinkling a plurality of reflective beads onto the exposed surface of said plastic and embedding the beads within the plastic before the plastic sets to form an inlay within the groove so that, when the plastic sets, the beads are held securely within the inlay and against loosening.

5. The method of making a sign as defined by claim 4 wherein said beads are embedded within the inlay be elevating and dropping said base onto a support prior to hardening of the plastic forming the inlay.

6. Themethod of making a sign as defined by claim 5 including the step of forming a cavity within said base adjacent the bottom of the groove to extend in a generally lateral direction away from said groove to receive a portion of said plastic when poured into said groove so that, when the plastic hardens to form said inlay, the

latter is locked securely within the groove. 

1. A sign with intelligible figures having en engraved appearance comprising a wooden base with a planar outer surface, an outwardly opening groove formed within said base and defining one of said figures, a thermosetting plastic inlay partially filling said groove and having an exposed surface spaced inwardly of and extending generally parallel with the outer surface of said base, a plurality of reflective beads embedded within said inlay, a cavity formed adjacent the bottom of said groove and extending laterally thereof into said base, a portion of said inlay being received within said cavity to lock said inlay within said groove, and a chamfer formed in said base and around said groove so as to slant away from said groove upon progressing outwardly from the exposed surface of the inlay toward the outer surface of said base thereby increasing the field of readability of said figure.
 2. A sign with intelligible figures having an engraved appearance comprising a base with a planar outer surface, an outwardly opening groove formed within said base and defining one of said figures, a thermosetting plastic inlay partially filling said groove and having an exposed surface spaced inwardly of and extending generally parallel with the outer surface of said base, and a chamfer formed in said base and around said groove so as to slant away from said groove upon progressing outwardly from the exposed surface of the inlay toward the outer surface of said base thereby increasing the field of readability of said figure.
 3. A method for making a sign with intelligible figures in a base comprising the steps of forming an outwardly opening groove within said base, filling the groove at least partially with a fluid plastic, placing a plurality of reflective beads on the exposed surface of said plastic, and embedding the beads within the fluid plastic by elevating and dropping said base onto a support prior to hardening of the plastic to form an inlay within the groove.
 4. A method for making a sign with intelligible figures having an engraved appearance in a wooden base comprising the steps of forming an outwardly opening gRoove within the outer surface of said base to define one of said figures, beveling the base around the edge of said groove to form a chamfer which slants away from said groove upon progressing outwardly from within said base toward the outer surface thereof, pouring a thermosetting plastic into said groove to a level approximately even with the inner edge of the chamfer, sprinkling a plurality of reflective beads onto the exposed surface of said plastic and embedding the beads within the plastic before the plastic sets to form an inlay within the groove so that, when the plastic sets, the beads are held securely within the inlay and against loosening.
 5. The method of making a sign as defined by claim 4 wherein said beads are embedded within the inlay be elevating and dropping said base onto a support prior to hardening of the plastic forming the inlay.
 6. The method of making a sign as defined by claim 5 including the step of forming a cavity within said base adjacent the bottom of the groove to extend in a generally lateral direction away from said groove to receive a portion of said plastic when poured into said groove so that, when the plastic hardens to form said inlay, the latter is locked securely within the groove. 